Robotic vacuum cleaner

ABSTRACT

An autonomous robot, that is for example, suitable for operations such as vacuuming and surface cleaning includes a payload configured for vacuum cleaning, a drive system including a steering system, a navigation system, and a control system for integrating operations of the aforementioned systems.

TECHNICAL FIELD

[0001] The present invention is related to robotic and other automateddevices and in particular to robotic and automated vacuum cleaning andother similar devices.

BACKGROUND

[0002] Robotics is a rapidly advancing field of technology. Today, forexample, robots appear in manufacturing production lines, operatingrooms, swimming pools, and warehouses. With the advance of thistechnology, robots are and will continue to perform more tasks that wereone thought to be only performable by humans.

[0003] However, one factor limiting the development of mobile robots istheir ability to move freely, absent motion restrictors such as tracks,guides, rails or the like, within a closed or working area, whileproviding complete coverage over portions of the closed or working area.Moreover, work over these desired or needed areas should be in anefficient manner, with some control over the travel path, so as not tobe repetitious or random, and therefore, wasteful of energy.

[0004] Motion restrictive mechanisms, such as tracks, guides, rails orthe like are disadvantageous, as they are unaesthetic, and expensive toinstall and maintain. Additionally, they present a workplace and/orpedestrian hazard, as they protrude from, or are indented, into floorsor the like. This may lead to injuries, should a person not be mindfulof them.

[0005] Another limiting factor is that robots for area coverage requiredboundaries, so as not to operate in undesired areas. These boundarieshave been either tracks rails guides, or other motion restrictors, whosedisadvantages have been detailed above, or markers, typically in theform of signs or other mechanisms, protruding from the ground, walls orceilings, that also present safety hazards as detailed above. Moreover,these signs or other boundary mechanisms are expensive to install andmaintain, as they must be precisely positioned and constantly watched byworkers to maintain the integrity of the boundaries.

[0006] Additionally, it is desired to extend the uses of robots fromcommercial uses, as detailed above, to domestic uses. In doing so, theperson who employs these domestic use robots will have increased free orleisure time, as they will be free from performing domestic tasks. Onesuch robot is disclosed in commonly owned U.S. Pat. No. 6,255,793, thatis incorporated by reference herein.

SUMMARY

[0007] The present invention improves on the contemporary art byproviding systems and methods for operating an autonomous machine,typically a robot, for performing tasks, for example vacuum cleaning.The apparatus of the present invention includes embodiments in the formof autonomous robots adapted for indoor or confined area coverage, thatcan be placed in a position within a room or the like and activated,such that the entire room will ultimately be covered and for example, bevacuumed, surface cleaned or the like. These embodiments can function inordinary rooms or areas with minimal, if any, room set up or preparationtime. The apparatus can move between various surfaces, such as hardfloors and carpets, without human intervention to change, brushes,nozzles or the like. Additionally, these embodiments can avoid obstaclesand cover the room or designated area with minimal repetition frompredetermined amounts of energy.

[0008] An embodiment of the invention includes an apparatus forautonomous vacuum cleaning comprising, a payload configured for vacuumcleaning, a drive system including a steering system, a navigationsystem, and a control system. The control system includes a processor,e.g., a microprocessor, that is configured for integrating operations ofthe payload, drive system and navigation system.

[0009] Another embodiment of the invention is directed to an apparatusfor autonomous operation over an area comprising a drive system and acontroller in communication with said drive system. This controllerincludes a processor, for example, a microprocessor, programmed to:provide at least one scanning pattern for a first portion of the area;analyze the first portion for an opening to a second portion of thearea; and signal the drive system to move along a path at leastproximate the periphery of the first portion to and through the openingto the second area.

[0010] Another embodiment is directed to an apparatus for autonomousoperation over an area comprising a drive system and a controller incommunication with the drive system. The controller includes aprocessor, for example, a microprocessor, programmed to: provide atleast one scanning pattern for a portion of the area from a first point;signal the drive system to move along a path at least proximate theperiphery of the scanned portion to a second point, the second point ata different location than said first point; and provide at least onescanning pattern for a portion of the area from the second point.

[0011] Another embodiment is directed to a method for area coverage byan autonomous machine, such as a robot or the like. This method includesscanning a first portion of the area in accordance with at least onescanning pattern, analyzing this first portion for an opening to asecond portion of the area, and moving along a path at least proximateto the periphery of the first portion to and through the opening to asecond portion of the area.

[0012] Another embodiment is directed to a method for area coverage byan autonomous machine, such as a robot or the like. This method includesscanning a portion of the area in accordance with at least one scanningpattern, from a first point; moving along a path at least proximate theperiphery of the scanned portion to a second point, the second point ata different location than the first point; and scanning a portion of thearea in accordance with at least one scanning pattern, from the secondpoint. In this method moving along the path to the second point can beeither a movement of a predetermined length (distance) or the length ordistance of travel can be determined dynamically.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Attention is now directed to the attached drawings, wherein likereference numeral or characters indicate corresponding or likecomponents. In the drawings:

[0014]FIG. 1 is a perspective view of the apparatus of an embodiment ofthe present invention;

[0015]FIG. 2 is a rear view of the apparatus of FIG. 1;

[0016]FIG. 3A is a bottom view of the apparatus of FIG. 1;

[0017]FIG. 3B is a front view of the apparatus of FIG. 1 with the bumpersection removed;

[0018]FIG. 4 is a perspective view of the apparatus of FIG. 1 with thehandle section lifted;

[0019]FIG. 5A is a cross section of the apparatus of FIG. 1;

[0020]FIG. 5B is a front perspective view of the apparatus of FIG. 1with the cover section removed;

[0021]FIG. 6A is a cross sectional view of the nozzle and agitator unitof an embodiment of the present invention;

[0022]FIG. 6B is a front view of the nozzle of FIG. 6A;

[0023]FIG. 7A is a bottom view of the rear portion of the apparatus;

[0024]FIG. 7B is a cross-sectional view along line 7B-7B of FIG. 7A;

[0025]FIG. 8 is a cross sectional view of an embodiment of a filtrationunit of the apparatus and a portion of the apparatus;

[0026]FIG. 9A is a perspective view of an embodiment of an impeller ofthe apparatus;

[0027]FIG. 9B is a cross sectional view of the impeller of FIG. 9A;

[0028]FIGS. 9C and 9D are sectional views of the impeller of FIG. 9A;

[0029]FIG. 10A is a sectional view of a rotating member of theapparatus;

[0030]FIG. 10B is a cross-sectional view of the rotating member of FIG.10A, taken along line 10B-10B;

[0031]FIG. 10C is a sectional view of a rotating member of theapparatus;

[0032]FIG. 11 is a perspective view of an alternate embodiment of arotating member, typically a brush, for the agitator unit of the presentinvention;

[0033]FIGS. 12A and 12B are top and bottom views of an alternate nozzleand agitator unit for the present invention;

[0034]FIG. 12C is a perspective view of an alternate agitator unit ofthe present invention;

[0035]FIG. 13 is a view of the bumper section of the cover and the shockdetection system; in accordance with an embodiment of the invention;

[0036]FIG. 14 is a perspective view of the shock detection system ofFIG. 13;

[0037]FIG. 15 is a perspective view of a drive wheel;

[0038]FIG. 16 is a sectional view of the support wheel assembly;

[0039]FIG. 17 is a perspective view of the apparatus in operation usingthe leash;

[0040]FIG. 18 is a cross sectional view of the leash assembly;

[0041]FIG. 19 is a perspective view of the nozzle height adjustmentsystem;

[0042]FIG. 20 is diagram of a door sensing system;

[0043]FIGS. 21A and 21B are diagram of the door sensing system inoperation with the apparatus of the invention;

[0044]FIGS. 22A and 22B are diagrams of a stair sensing system inoperation with the apparatus of the invention;

[0045]FIG. 23 is a schematic diagram of the control system for theapparatus of the invention;

[0046]FIGS. 24A and 24B are flow diagrams of an example navigationprocess used by the apparatus of the invention; and

[0047]FIG. 25 is a diagram of a system for confining the apparatus inaccordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0048]FIGS. 1, 2 and 3A show the apparatus 20 of the present inventionin an exemplary configuration as a robotic vacuum cleaner. The apparatus20 includes a cover 22, formed of sections 100, 101, 104 and 106(detailed below), with openings 24 a-24 g in the bumper section (bumper)104. There is also a control panel (user interface) 25, supported on themain sections 100, 101. This control panel 25 includes various controlknobs 26 a, indicators 26 b (Light Emitting Diodes (LED) or the like),26 c (LED Display or the like), as well as a socket 27 for receiving acord (plug end or the like) for charging the apparatus 20 in anelectrical outlet or the like. A leash 28 also extends from this controlpanel 25.

[0049] The apparatus 20 includes sensors, that are part of sensingsystems. Door detection sensors 30 a, 30 b in openings 31 a, 31 b are onor near the control panel 25 on the upper side of the apparatus 20. Thefront side of the apparatus 20 includes contour sensors 34, 35 (FIG. 13)for lateral obstacle and wall detection, in openings 24 a and 24 b (FIG.13), frontal obstacle detection sensors 36 a, 36 b in openings 24 c and24 d, corner sensors 37, in openings 24 e, a shelf detection sensor 38in opening 24 f and remote control sensors 40 in upper opening 24 g andlateral openings 24 h (see also FIG. 13). These sensors 40 receivesignals, typically infrared (IR) light signals, from a remote controller46 or a coded transmitter 1300, as shown in FIG. 25 and detailed below.

[0050] The apparatus 20 is formed of multiple systems, including a powersystem, drive (motion) system, navigation system, payload, or vacuumingsystem, bumper system, sensing (including obstacle detecting) systems,all coupled to a control system 1000 (FIG. 23), allowing for autonomousoperation. This autonomous operation includes for example, vacuumcleaning or vacuuming, and other surface cleaning operations andmovement therefore, by the apparatus 20. The apparatus 20 also includesnumerous other systems, shown and detailed below.

[0051] Turning also to FIG. 3B, the apparatus 20 is formed of a chassis50, having a base 52 and an extending portion 54 (FIG. 4), forsupporting the components and systems (detailed herein). The chassis 50rests on drive wheels 72 and a support wheel 74, the drive wheels aretypically limited to a single degree of freedom and are “active”, witheach drive wheel 72 controlled by conventional axial drive mechanisms 73(motors, etc.-FIG. 19). The support wheel 74, is “passive”, andtypically has having multiple degrees of freedom, as it is used forposition, distance and orientation control of the apparatus (shown inFIG. 16 and detailed below). This support wheel 74 is for example, acastor wheel, as detailed in FIG. 16 below.

[0052] In normal operation, the drive wheels 72 are forward of thesupport wheel 74, such that the apparatus 20 moves in the direction ofthe arrow 75, this arrow indicating the “forward” direction.Accordingly, for description purposes of this document, the terms“forward” and “front” will refer to direction or orientation from thesupport wheel 74 to the drive wheels 72, while the terms “rear” and“backward” will refer to the direction or orientation opposite of arrow75, the direction from the drive wheels 72 to the support wheel 74 (andassociated electronics). Drive wheels 72 are driven independently ofeach other, so as to allow for steering (turning and directionalchanges), and define the steering system 1030 (FIG. 23). These drivewheels 72 (forming the steering system 1030) couple with the supportwheel 74, to form the drive system 1040 (FIG. 23). The steering system1030 and drive system 1040 couple with the control system 1000.Additionally, the drive wheels 72 and support wheel 74 couple with thenavigation system (processed through the microprocessor 1004 in FIG.23).

[0053] Turning also to FIG. 4, battery housings 85 (only one shown),envelope batteries 86, typically 12 volt batteries, typicallyrechargeable, or other similar power source(s) that provide power to theapparatus 20. The battery housings 85 include handles 87, for ease inplacement and removal of the batteries 86 (by a user 88) into and out ofthe apparatus 20. The housings 86, typically at their bottom sides,include electrical plugs (not shown) for receipt in correspondinglyconfigured sockets (not shown) on the chassis 50, or vice versa, orother suitable paired electrical contacts. The sockets couple with powerdistribution electronics, to provide power to all components and systemsof the apparatus 20, as well as the control system 1000. The batteries86 and associated electronics and circuitry (detailed above) form thepower system 1070 (FIG. 23) for the apparatus 20.

[0054] There is also a charging system 1074 (FIG. 23) formed by acharging module (not shown), and associated circuitry. The chargingmodule is electrically coupled to the batteries 86. The charging moduleis also connected to the socket 27 or port, that can connect with anelectrical line, that plugs into a conventional wall socket or the like,to provide electricity to the charging module and ultimately to thebatteries.

[0055] The cover 22 is typically formed in sections 100, 101, 104, 106.There are two underlying or main sections 100, 101, mounted to theextending portion 54 of the chassis 50 in a fixed manner, overlapped inthe from of the apparatus 20 by a bumper section (or bumper) 104 and inthe rear of the apparatus 20 by a handle section 106. The handle section106 includes openings 108,118 where the filtration unit 148 (FIG. 8) isviewable and a handle 106 a is formed from the handle opening 118.

[0056] The bumper section 104 is pivotally mounted on the apparatus 20as it mounts (along its inner wall 110) to the bumper member 360, asshown in FIGS. 13 and 14 and detailed below. This mounting suspends thebumper section 104, allowing it to absorb impacts for the apparatus 20.This bumper section 104 covers an arc of approximately 200 degrees(front and sides). Accordingly, this bumper section can handle frontaland lateral impacts to the apparatus 20 as well as impacts from pointsalong the top of the apparatus 20. This bumper section 104 forms part ofthe shock detection or bumper system 1082 (FIGS. 13, 14 and 23) anddetailed below.

[0057] The handle section 106 is pivotally mounted to the extendingportion 54 of the chassis 50. This section 106 includes an opening 118,that when the apparatus 20 is in a use position, snap-fits into the mainsection 100. The opening 118 is dimensioned such that the filtrationunit 148 (FIG. 8), can be viewed. When the apparatus 20 is in thenon-use position, the lower portion of the section 106 is pivotedupward, whereby it is a handle 106 a, allowing the apparatus 20 to becarried by the user.

[0058] Turning additionally FIGS. 5A and 5B, there is detailed thepayload 130 of the apparatus 20. The payload 130 will be discussed alongwith other components from other systems, that are explained hereinbelow. The payload 130, for example, is a vacuum cleaning system, andincludes a nozzle 140 that connects to a tube 142, through a duct 144.The tube 142 extends into, and is typically part of, a filtration unit148 (also in FIG. 3), that includes filter elements 150 and a particlecollection area 152.

[0059] A conduit 154 connects the filtration unit 148 to an impellerchamber 156, that houses an impeller 158, that is rotated by a motor160. The impeller chamber 156, that houses the impeller 158 and motor160, is typically formed of shells 161 a, 161 b joined by mechanicalfasteners, adhesives or other conventional arrangements, a supportmember 162 (attached to the chassis 50), along a rim 162 r. The supportmember 162 includes a vent 163, formed of bars 163 a, the vent 163 opento the ambient environment. This allows for air intake for suction (inthe direction toward the impeller 158, or downstream for purposes ofthis document). This arrangement forms a flow path for particles, thatis considered to be indirect, since the filtration unit 148 is beforethe impeller 158, in the particle flow path.

[0060] An agitator unit 164 is at the base of the nozzle 140. Thisagitator unit 164 includes a cover 164 a typically includes acompartment 165 for accommodating rotating members 166 a, 166 b, and ispositioned upstream of the nozzle 140. The rotating members 166 a, 166 bare typically brushes or the like, whose rotation is controlled by aconventional rotator motor 308. The agitator unit 164 may includerollers 168 or the like for contact with the surface or ground 183, andmay be mounted onto the chassis 50 in a manner, so as to contact theground or surface 183, providing resistance to it, and adjust to variouslevels in accordance with the contour of the ground or surface. Theremay also be a static brush portion 169 intermediate the rotating members166 a, 166 b.

[0061] The cover 164 a, for example, at its front, begins at a height hhoff of the ground 183 (for example, approximately 2 to 4 cm), exposingthe rotating members 166 a, 166 b, so as to be an “open brush”. This“open brush” construction, allows obstacles to be agitated by therotating members 166 a, 166 b and suctioned away for enhanced cleaningand obstacle free movement of the apparatus 20. These rotating members166 a, 166 b in this construction can assist with drive movements.

[0062] Turning also to FIGS. 6A and 6B, the nozzle 140 includes a neck170 and a body 172, that form an inner cavity 174 for particles (e.g.,debris, etc.) to pass through. At one end, the neck 170 terminates in anopening 176 for attachment to the tube 142 of the filtration unit 148.The other end extends to an outwardly tapered portion of the body 172.The body 172 terminates in a lip 178, that is typically rounded, with anopening 180. This opening 180 includes a first, and typically upper edge180 a, and is narrow at its middle 180 m or midsection and wide at thesides 180 s, as a result of the tapering (upward, away from the ground183) of the lip 178, so as to have uniform airflow into the nozzleopening 180.

[0063] The body 172 also includes sidewalls 172 a, that border a cutoutedge 182. This cut out edge 182 defines a second, typically lower, edgeof the opening 180, and provides for ground clearance and greatermaneuverability. The horizontal orientation of the nozzle body 172,coupled with the lip 178 extending beyond the cutout edge 182, allows aflow cavity to be formed with the floor or surface 183. This cavity isof a constant vertical aperture with respect to the opening 180, asindicated by typically equal lengths 180′. This constant verticalaperture maintains acceleration of the airflow into the nozzle opening180 and nozzle body 172. Additionally, the cavity, coupled with theshape of the rotating members 166 a, 166 b creates a horizontalacceleration channel with horizontal air flow for particulates (debris,etc.) into the nozzle 140.

[0064] Turning also to FIGS. 7A and 7B, arms 184 extend laterally fromthe neck 170 and terminate in blocks 186. The blocks 186 are mounted inboxes 188, with receiving portions 189, outer sidewalls 189 a and inner(cut-out) sidewalls 189 b. As detailed in FIG. 7B, the blocks 186 areforced into the receiving portions 189 by biasing members (typicallyflexible), for example, springs 192, that extend inside the blocks 186and can be covered with an electrically insulation sheath 192 a tube orthe like, and frictionally retain the blocks 186 in the boxes 188. Thesprings 192 can also be made of nonconducting material, for example,plastics or non-conducting metals (to avoid a short circuit between theplates 194, 198 and the spring 192, detailed below). This arrangementprovides the blocks 186 with the ability for pivotal movement therein,ultimately allowing the nozzle 140 to pivot about the boxes 188.

[0065] The boxes 188 include electrical contacts 194, 195, typicallymetal sheets, plates, or the like, in communication with wiring 196(from wire leads 196 a) linked to the control system 1000. The blocks186 include a metal plate 198 at one end and a metal stub 199 (also FIG.6B) at the other end (along the arm 184), also connected by the wiring196. The plates 194, 198 between the respective boxes 188 and the blocks186, form “normally open” contacts, while the respective plates 195 ofboxes 188, and stubs 199 form “normally closed” contacts. This series ofcontacts and associated electronics defines a nozzle obstacle detectionsystem 1080 (FIG. 23).

[0066] In operation, the open contact (plates 194, 198) and the closedcontact (plate 195 and stub 199) are registered with the control system1000. Should the nozzle 140, upon its movement encounter a hard object,obstacle, or the dragging force become too great, the nozzle 140 willmove. If the force is great enough, and movement of the nozzle 140closes any of the normally open contacts, such that the plate 198physically contacts the plate 194, and/or opens the physical contactbetween the plate 195 and the stub 199, a signal, typically indicating aclosed or open circuit respectively (from the initially open and closedcircuits, respectively), will be sent to the control system 1000.

[0067] With the requisite signal sent to the control system 1000, thecontrol system 1000 will signal the nozzle/rotating member heightmechanism 560, to raise the nozzle 140 (and the rotating members 166 a,166 b attached thereto) over the obstacle. With the nozzle 140 androtating members 166 having cleared the obstacle, travel of theapparatus 20 continues as normal. Alternately, the control system 1000can be programmed to signal the drive system 1040 to cease operationimmediately. (This is also true for other drive system stoppagesthroughout this document, that are not specifically detailed).

[0068] The nozzle 140 is typically made of resilient materials, such asplastic (HDPE, PVC, Nylon, etc.) and is easily separable from both thebase 52 of the chassis 50 and the agitator unit 164. The nozzle 140typically snaps into the base 54 with the agitator unit 164 snappinginto the nozzle 140, in a “tools free” manner. For example, the agitatorunit 164 snaps into the nozzle 140 as edges 204 of the agitator fit intoslots 206 on the nozzle 140 (FIGS. 6A, 6B and 19). This engagement isheld together by a resilient clip 208 on the agitator unit 164 having aspike (not shown) on its lower surface, the engages a correspondinglyconfigured opening (not shown) on the nozzle 140, holding the nozzle 140and agitator unit 164 together. This snap-together arrangement allowsfor different nozzles to be placed onto the apparatus 20. Thesedifferent nozzles are designed for the specific type of particulate andsurface that the apparatus 20 is to be operated on.

[0069] Turning also to FIG. 8, the tube 142 is formed of a neck 222 andan outwardly tapered head portion 224. The head portion 224 is typicallyof a diameter larger than the neck 222, and is of a configuration topush particles around the filter element 150 (having pleats 150 a), thatis open on its lateral sides and above it. This results in aircirculation along the pleats 150 a, that causes a self-cleaning effect,resulting in longer life for the filter element 150. Pressure loss isminimized due to reduced blockage of the material forming the filterelement 150.

[0070] This filtration unit 148 is a box-like article of a transparentmaterial, such as plastic or the like, to allow for full bin sensing(detailed below) and inspection by viewing. It can be easily removed, bylifting, from the apparatus 20, when the handle section 106 is lifted(as shown in FIG. 4). It typically separates into two pieces 230, 231(allowing for emptying of dirt held therein), that when placed togetheralong edges 230 e, 231 e, lock in a frictional engagement. A fist piece230 forms the bottom of the unit 148, with its inner side serving as theparticle collection area 152 or dirt cup.

[0071] The preferred material for the filter 150 is a material having apermeability of approximately 100 CFM per square foot.

[0072] Proximate the filtration unit 148 and within the apparatus 20 isa light transmitter 232 and a light receiver 233, that coupled with therequisite electronics, form a full bin sensing system 1020 (FIG. 23).The transmitter 232 and receiver 233 communicate with the filtrationunit 148 through openings 232 a, 233 a in the extending portion 54 ofthe chassis 50 that borders the filtration unit 148. The lighttransmitter 232 and light receiver, with associated electronics, coupleto the control system 1000. A “full bin” is sensed when dirt hasaccumulated in the filtration unit 148 to a point where lighttransmitted from the transmitter 232 can not be detected by the receiver233. A signal is then sent to from the control system 1000, for example,to an indicator light 26 b indicating a full bin. (The filtration unit148 can be removed and emptied as detailed above).

[0073] FIGS. 9A-9D show the impeller 158 in detail. The impeller 158 isconstructed to pull particulates downstream upon rotation by the motor160. The impeller 158 includes a central member 250, typically conicalin shape, with a bore 251 therein for accommodating a motor shaft 270 orthe like and plates 254, 255, with two types of blades 256, 258therebetween. The upper plate 254 for example, has a radius of curvatureRA of approximately 53 mm, while the conical portion 250 defining thelower plate 255 has a radius of curvature RB, for example, ofapproximately 39 mm.

[0074] These blades 256, 258 include short blades 256, that typicallyextend from at least proximate the ends of the plates 254, 255 to apoint before the conical contour of the central member 250, and longertwisted blades 258, that extend from at least proximate the ends of theplates 254, 255 to the conical contour of the central member 250. Theupper plate 254 includes an opening 262 to receive portions of thetwisted blades 258.

[0075] Blades 256, 258 are typically arranged in threes, with typicallytwo arced (or short) blades 256 between each twisted blade 258. Thereare typically five series of these three blade arrangements (two shortblades and one twisted blade). Arced blades 256 are typically curved, soas to have exit angles α, typically 30±5 degrees, while twisted blades258 typically are curved such that exit angles β are typically 30±5degrees. These twisted blades include an upper blade twist angle λ alongthe conical portion 250 of for example, approximately 10 degrees, and aninput angle Φ of approximately 60 degrees, and a radius of curvature RXof for example, approximately 9 mm.

[0076] The blades 256, 258 are typically arced in the same direction,between the plates 254, 255. This configuration of blades 256, 258provides for high impeller efficiency of approximately 60%. (Thisefficiency defined by the output airflow divided by the motor inputpower). The impeller 158 is typically an integral, one piece structure,made of hard plastic, such as HDPE, PVC, Nylon. It is typically made bytechniques such as injection molding or the like.

[0077] The motor 160 is typically an 80 watt standard motor, or othersimilar motor. It includes a shaft 270 extending therefrom, to which theimpeller 158 attaches. This motor 160 is electrically connected to thepower system 1070, and can operate at relatively low RPMs, for examplehere, the motor 160 may operate at approximately 7500 rpm. By operatingat low RPMs, the motor operates at a low noise level and is energyefficient. The motor 160 is held on a motor support 272 (FIG. 5A), thatmay be incorporated into the support member 162.

[0078] Turning to FIGS. 6A and 10A-10C, the agitator unit 164 includesrotating members 166 a, 166 b, typically brushes. These rotating members166 a, 166 b are joined together by a pulley 300, attached thereto, thatis received in a belt 302. The other end of the belt 302 is received bya shaft 306 of a motor (agitator motor) 308, that rotates the shaft 306,the motor 308 operated by the control system 1000.

[0079] Speed of the rotating members 166 a, 166 b (i.e., brushes) can bechanged according to surface type, detected by the method detailed belowand signaled to the control system that signals the motor 308, ormanually entered into the control system 1000 by the user (typically viathe remote controller 46 or through the user interface 25). For example,the rotating members 166 a, 166 b or brush speed may be approximately3000 RPM on carpet, and about 500 RPM on hard floors. The low RPM onhard floors is to eliminate particles from escaping under the nozzle 140due to their high energy. This problem does not exist in carpets sincethere is not a gap between the nozzle 140 and the carpet.

[0080] One method for defining or detecting the surface type is bymeasuring the load on the motor 308 that drives the rotating members 166a, 166 b (brushes). This is due to a difference in load on the motor 308between hard floors and medium to deep (e.g. medium to deep pile)carpets. These loads are signaled to the control system 1000, thatprocesses this information and signals the motor 308 to rotate therotating members, at the above described speeds for hard floors andcarpets respectively.

[0081] When on deep carpets, the height of the rotating members 166 a,166 b is relative to the position of the drive wheels 72, so that indeep carpets (e.g., deep pile carpets) a noticeable height can bemeasured as the drive wheels 72 sink in the carpet, while the rotatingmembers 166 a, 166 b, float on the carpet. Accordingly, the controlsystem 1000 can detect that deep carpet is the surface over which theapparatus is traveling 20, as detailed below. Based on this heightdetection, the control system can signal the motor 308 to theaforementioned speeds. For example, greater heights with respect to thesurface 183 are indicative of carpets, and thus, the control system 1000signals the motor 308 to rotate the rotating members 166 a, 166 b at thehigh speed, of approximately 3000 RPM. Alternately, lower heights withrespect to the surface 183 are indicative of hard floors, and thus, thecontrol system 1000 signals the motor 308 to rotate the rotating members166 a, 166 b at the low speed, of approximately 500 RPM.

[0082] These two surface detection mechanisms typically operatedynamically and “on the fly”. They are typically sufficient in detectingmost surfaces. However, the aforementioned surface detection mechanismsmay be of lesser accuracy with respect to low or low pile carpets.

[0083] Accordingly, the motor 308 and rotating members 166 a, 166 b, ascoupled with the control system 1000, can also serve as a third surfacedetection mechanism. This system is particularly effective in detectingthese low or low pile carpets. This is done in the microprocessor 1004,that will analyze the load on the motor 308 for the rotating members 166a, 166 b as a function of resistance provided by the surface beingtraversed. This detection mechanism involves a short shut down of themotor 308, for example, approximately 0.5 seconds. Accordingly, rotationof the rotating members 166 a, 166 b ceases. If the surface or groundprovides resistance to the rotating members 166 a, 166 b, thisresistance and resulting movement (rotation) of the rotating members 166a, 166 b, will result in a back electromotive/electromagnetic force(EMF) on the motor 308, that is measured as a voltage. Thesemeasurements are sent to the control system 1000, that signals the motor308.

[0084] For example, where back EMF is low to negligible, the surfacebeing traversed is most likely a hard floor, whereby the control system1000 will signal the motor 308 to rotate the rotating members 166 a, 166b, at a slow speed, typically approximately 500 RPM for hard floors, asdetailed above. Alternately, where back EMF is large, the surface beingtraversed is most likely a carpet, such as the low or low pile carpet,whereby the control system 1000 will signal the motor 308 to rotate therotating members 166 a, 166 b, at a high speed, typically approximately3000 RPM for carpets, as detailed above.

[0085] Turning to FIGS. 10A-10C, the rotating members 166 a, 166 b willbe described with respect to a single rotating member 166 a, that isexemplary of both rotating members 166 a, 166 b. Accordingly, allcomponents of both rotating members 166 a, 166 b are the same and arenumbered as such, except for grooves 314 a, 314 b, that are the same inconstruction, but are numbered differently to illustrate operationalprinciples, as detailed below. The rotating members 166 a, 166 b bothinclude a core 316 of diameter DC and a helical groove 314 a, 314 b,respectively, that extends into the core 316. Diameter DC is typicallylarge, for example, approximately 30 mm, resulting in a typically largeperimeter of approximately 10 cm, so as not to allow fringes or othercarpet or rug fragments to wrap around the core 316. The groves 314 a,314 b include a leading edge 318, that is preferably straight and atleast substantially parallel with respect to the vertical, and atrailing edge 319 that is preferably rounded. (The leading edge 318 andtrailing edge 319 of the grove 314 a, 314 b are referred to as such, inaccordance with the preferred rotational direction of the rotatingmembers 166 a, 166 b, indicated by arrow RM.) Bristles 320, anchoredinto the core 316 of the rotating member 166 a, 166 b, by conventionalfastening techniques, extend from the core 312, through the groove 314a, 314 b to slightly beyond the outer surface 322 of the rotating member166 a, 166 b. By resting in the grooves 314 a, 314 b and the grooves 314a, 314 b dimensioned as detailed herein, the bristles 320 can bend, soas not to inhibit torque on the rotating members 166 a, 166 b. Thesebristles 320 are typically made of nylon or the like.

[0086] The rotating members 166 a, 166 b are connected to the pulley 300at an orientation where the respective grooves 314 a, 314 b form a “V”,such that these grooves 314 a, 314 b spiral outward from the center ofthe apparatus 20. This orientation of the grooves 314 a, 314 b, coupledwith their construction, the diameter of the core 316, bristle 320arrangement in the grooves 314 a, 314 b and length, moves dirt towardthe center or inward into the nozzle 140. These rotating members 166 a,166 b are also detachable, and can be replaced with other suitablebrushes or the like.

[0087] Alternately, as shown in FIG. 11, there is an alternate rotatingmember 166′, typically a brush with a core 312′, that is attached to theagitator unit 164 as detailed above. The rotating member 166′ is similarin all aspects to the rotating members 166 a, 166 b, except whereindicated. The rotating member 166′ is formed of resilient members 320′,for example, of hard plastic, rubber or the like, embedded therein orattached thereto. Upon rotation of the brush, the rotating members 320′strike the surface with a force sufficient to agitate or bring upparticulates. These members 320′ can also bend, so as to keep torque onthe rotating member 166′ at suitable levels for proper operation.

[0088]FIGS. 12A and 12B detail alternate embodiments of the nozzle 140′and for the agitator unit 164′. All components are the same as those inthe nozzle 140 and agitator unit 164 detailed above, except whereindicated. In the nozzle 140′, there are protrusions 328 at the nozzleopening 180, to make airflow uniform at the nozzle opening 180. In theagitator unit 164′, the rotating members have been replaced by aclapping unit 330. The clapping unit 330 attaches to the nozzle 140 by aplate 331, via screw mechanisms 331 a or the like. This clapping unit330 includes the pulley 300 attached to a rod 332, on which areconnected wheels 334 and cams 335 with lips 335 a, that upon rotation ofthe rod, move clips 338, by lifting their flanges 338 a, up and down,typically at different times (although all at the same time is alsosuitable), to create agitation of particulates for suction.

[0089]FIG. 12C details another alternate embodiment agitator unit 164″.Here, there are two motors 340 a, 340 b, that typically rotate cams 342a, 342 b in opposite directions, as indicated by the arrows 343 a, 343b. However, the same direction for rotation is also permissible.Non-motorized cams 344, mounted to the apparatus 20 support belts 345the include bristles 320″. The belts 345 and bristles 320″ travel in adirection substantially perpendicular to the direction of travel of theapparatus 20 (indicated by arrow 75). This substantially perpendiculardirection of travel is sufficient to create the requisite agitation ofparticulates for suction as detailed above.

[0090]FIGS. 13 and 14 (in FIG. 14, the support member 162 is partiallycut away) detail the shock detection system 1082 (FIG. 23) for theapparatus 20. This system includes bumper member 360, having rods 362received in oppositely disposed lateral supports 364, that abut lateralsegments 162 a, typically having an inverted “L” shaped contour, on thesupport member 162. The rods 362 are hooked to springs 366, that in turnare hooked to the vent bars 163 a of the support member 162. The springs366 pull the rods 362 upward, such that the lateral supports 364 engagethe lateral segments 162 a. This attachment provides the ends of thelateral supports 364 with pivotal movement at pivot points 365 a, 365 b,from the lateral segments 162 a. This pivotal movement may occur uponfrontal or top impacts to the apparatus 20. The lateral supports 364include oppositely disposed protrusions 370 that are received incorrespondingly configured tracks 372 on the inner wall 110 of thebumper section 104 (only one shown). The positioning of the bumpermember 360 in the apparatus 20 is such that shock detection is providedalong an arc of approximately 200 degrees.

[0091] The bumper section 104 is supported at its center of gravity,inhibiting tilting torque from developing during acceleration anddeceleration of the apparatus 20. The linear force on the center ofgravity during acceleration, is balanced by the spring 366 force, wherethe front mounting eliminates any movement during deceleration.Additionally, the bumper section 104 and bumper member 360 are connectedsuch that a static force of approximately 0.26 kilograms (Kg) on theupper and lower ends of the bumper section 104 and increasing to astatic force of 1.2 Kg at the center will activate a signal to thecontrol system 1000 that the bumper section 104 has contacted anobstacle and for example, the drive system 1040 must be signaled tocease motion, by the control system 1000. Typically, the drive system1040 will stop motion, such that the apparatus 20 has traveled not morethan approximately 15 cm from the time of impact with the obstacle.

[0092] The rods 362 are connected by a central member 374, that restsbetween arms 376 from a spring 378. These arms 376, each rest in grooves380, within a guide 382, and while movable, provide a resistive forceagainst lateral movement of the central member 374, in the case of sideimpacts on the apparatus 20.

[0093] Metal clips or plates (not shown) extend along the inner sides ofthe lateral supports 364, and contact metal members (not shown) at thepivot points 365 a, 365 b on the lateral segments 162 a, to formelectrical contacts. Arms 376, also of a metallic material, contact ametal band 388 on a member 390 rearward of the guide 382. In the case ofa front impact of sufficient force (overcoming that of the springs 366),the bumper member 360 will be moved pivotally. There are also electricalleads 392 throughout this member 360 to which wires or the like areconnected for coupling with the electronics of the control system.

[0094] In operation, if at least one of the four electrical contacts atthe pivot points 365 a, 365 b is broken, typically as a result of afront, side or top impact to the apparatus 20, a signal will then besent to the control system 1000, that will then, for example, signal thedrive system 1040 to cease motion immediately. In the case of a sideimpact, the bumper member 360 will move laterally, such that thismovement causes at least one of the arms 376 to move out contact withthe band 388. This will also cause a signal to be sent to the controlsystem 1000, that will then, for example, signal the drive system 1040to cease motion. Specifically, these pivotal and lateral movements arecaused by contact to the bumper section 104 at the front of theapparatus 20. The bumper member 360 is configured for example, such thatmovements of approximately 2 mm or greater to the bumper section 104 orforces as detailed above, will cause these pivotal or lateral movements,to occur, whereby at least one requisite electrical contact is made orbroken. This change in electrical contact will result in a signal beingsent to the control system 1000, that will signal the drive system 1040to stop, ceasing motion of the apparatus 20 (as detailed above). Motionceases within the depression limits of the bumper member 104, that istypically not more than 20 mm.

[0095]FIG. 15 shows a drive wheel 72 (representative of both drivewheels), that typically includes a tread portion 72 t formed of lateralprotrusions 72 a, defining outer rows, with central “+” shapedprotrusions 72 b, defining an inner row. This provides the drive wheel72 with increased traction, to minimize slippage along various surfaces,for example, hard floors and carpets. This allows for precise movementof the apparatus 20. The drive wheel 72 at this treaded portion istypically made of a soft rubber or the like.

[0096] The protrusions 72 b of the inner row are “+” shaped so as to bereinforced laterally, to establish a central point for turning. Theprotrusions 72 a of the outer rows are flexible laterally, to smooth thedrive path and are flexible laterally allowing for turning with minimalmovement of the turning center. The gaps between protrusions 72 a of theouter rows, improve climbing on carpets, should the carpet be approachedfrom an angle.

[0097]FIG. 16 shows the support wheel 74 in an assembly that withassociated electronics forms a portion of the drive system 1040 (FIG.23) that couples to the control system 1000. The support wheel 74 is,for example, a castor wheel, typically formed of two shells 400 a, 400 b(FIG. 2), so as to have a hollow inner chamber 402. For additionaltraction, there can be a band 403 (FIG. 2), made of rubber or the like,placed around the support wheel 74. Here, there are magnets 404, orother metal objects detectable by magnets or the like. The shells 400 a,400 b also include aligned bores 408 for receiving the axial portion 410of a movement arm 412 (the other portion of the movement arm 412 beingthe main portion 414). The support wheel 74 tracks odometry and anglesof travel, to signal the control system 1000 for determining directionand orientation of the apparatus 20.

[0098] The movement arm 412, at its main portion 414 is rotatablymounted within a sensor unit 416. This sensor unit 416 includes several,typically three, magnetic field sensors 418, such as hall effectsensors, located over a circle around the arm 412. These sensors 418send signals to the control system 1000.

[0099] The positions of the magnets 404 in the wheel inner chamber 402,based on the angle with respect to the horizontal, coupled with therotations of these magnets 404, are utilized by the control system 1000,in an odometer function, to determine total displacement. By monitoringthe signal obtained from the magnetic field sensors 418, both the traveldistance and the orientation of the castor wheel 74 can be determined(the distance is obtained by counting the number of pulses induced bythe traveling magnets 404 where the angle is calculated by comparing thestrength of signal between the magnetic field sensors 418).

[0100] Based on these calculations of distance and displacement, thecontrol system 1000 can adjust the steering 1030 and drive 1040 systemsaccordingly, to properly position the apparatus 20. The control system1000 with this information can also control the navigation systemaccordingly.

[0101] Turning to FIGS. 17 and 18, there is the leash 28 as detailedabove. The leash 28 is a wire 508 or the like, and includes a balled end510 and a coiled end 512, typically wrapped around a spring biasedroller 514 in the body of the apparatus 20. The wire 508 extends througha mechanical member 520, intermediate its ends.

[0102] The mechanical member 520 includes a body 522, and oppositelydisposed ring members 524, 525 with hemispherical protrusions 524 a, 525a resting in each other in alignment. Ring members 524, 525 also includea tubular guide 524 b, 525 b. Upper ring member 525 is held in place bya spring 528, that is held in place by the body cover 530 and the neck525 c of the ring member 525. This spring 528 allows for movement of theupper ring member 525 when the leash 28 (wire 508) is pulled. Asensor(s) 540, coupled to the control system 1000, connects to the ringmembers 524, 525 and detects which protrusions 524 a, 525 a, weretemporarily pulled out of alignment, and signals this back to thecontrol system 1000. The control system 1000 recognizes this direction,and powers the drive wheels 72 accordingly, with the direction andorientation of the apparatus determined by the support wheel 74 and itssensors reporting to the control system 1000.

[0103] Turning now to FIGS. 3B and 19, there is a nozzle heightadjusting system 560 (FIG. 23), coupled to the control system 1000, thatraises and lowers the nozzle 140, in response to the surface, and insome cases, obstacles detected. The nozzle 140 includes a bracket 561with an opening 562 therein. This opening 562 is engaged by a rod 564attached to an adjustment mechanism 566, and with associatedelectronics, is coupled to the control system 1000. The nozzle 140 isspring mounted, and can be pushed upward, to contact a metal or magneticportion 570 of a member 572 within a spring 573. The end of the metalmember 570 is detected by a magnet (magnetic sensor) 580, for example, ahall effect sensor, that senses a position change for the member 572,and will indicate this change, via signals or the like to the controlsystem 1000, that will signal the adjustment mechanism 566, typicallyincluding a motor 566 a. This motor 566 a will drive an eccentric member566 b, that translates rotation to vertical movement by moving the rod564, and therefore the nozzle 140 up to the proper position. (The nozzle140 will move down provided there is open space between the rotatingmembers 166 a, 166 b, i.e., brushes, and the surface, as detailedbelow).

[0104] The nozzle height adjustment system 560, in particular theadjustment mechanism 566, typically functions to set only the minimumheight for the nozzle 140 and rotating members 166 a, 166 b (i.e.,brushes) (since the nozzle 140 is attached to the rotating members 166a, 166 b, they are treated as a single unit-nozzle/rotating members, forpurposes of this example description). Accordingly, it can adjust thenozzle 140/rotating members 166 a, 166 b, for higher surfacesautomatically, since the nozzle 140/rotating members 166 a, 166 b cantravel freely upward. The minimum height is required to keep the nozzle140/rotating members 166 a, 166 b (i.e., brushes) at a desired height,and therefore reducing the load on the nozzle/rotating members, asinduced by the carpet. On hard floors or other surfaces, the rollers 168maintain the nozzle 140/brushes 166 a, 166 b at the correct height.

[0105] The measurement of height for the rotating members 166 a, 166 b(i.e., brushes) is also suitable for determining surface types, inparticular, carpets versus hard floors or other surfaces. This can beachieved because the brushes 166 a, 166 b and nozzle 140 have a degreeof freedom in the upward direction, and therefore, can follow the levelor contour of the surface on which they are riding. For example, incarpets, the rollers 168 sink slightly, the brush height in relation tothe rollers 168 will be different from this height on a hard floor, andthus the surface type can be determined.

[0106] The various sensors and systems formed by combinations thereofare further detailed below. All of these sensors are electricallycoupled to the control system 1000, that in turn signals the drivesystem 1040 and drive wheels 72 to operate in various modes, dependingupon the obstacle or opening detected.

[0107] Turning also to FIGS. 20, 21A and 21B, door detection sensor 30 ais typically formed of formed of two infra-red (IR) transmitters 600 a,600 b, while the other door detection sensor 30 b is typically formed ofan IR receiver(s) 602. The transmitters 600 a, 600 b are positioned atan angle Θ, with respect to each other, that is, for example,approximately 20-30 degrees, and at a distance zz from each other, forexample, approximately 10 mm. One transmitter, here, transmitter 600 a,and the receiver 602 are typically also tilted approximately 5 degrees(into the plane of the paper). This titling limits potentially unwantedreflections from horizontal highly reflective surfaces such as metaldoor frames, mirrors, lights, reflectors, etc., since most of the lightenergy in these cases will be projected 10 degrees forward rather thanreturning to the receiver 602.

[0108] Door or boundary detectors include retro-reflectors 606(reflectors that reflect light back at approximately the same anglereceived), typically sticker-like, of which one or more can be placed onthe floor proximate the door 608 and/or within the doorjamb itself.Should a floor or wall boundary be desired, the retro-reflector 606 maybe placed on the floor or wall, and similarly, the retro-reflector 606may be placed on the ceiling to define the desired wall or floorboundary.

[0109] The transmitters 600 a, 600 b, by being arranged at this angle θcan detect the desired doors, and entryways for these doors, whiledistinguishing them from other locations, such as under tables, countersor the like. In operation, the transmitters 600 a, 600 b, emit lightbeams 609 a, 609 b (illustrated in FIGS. 21A and 21B for descriptionpurposes). The range for the receiver 600 is also represented by a beam610 (also, only for description purposes).

[0110] In FIG. 21A, should a door be detected, the receiver 602, willdetect a reflection from the corresponding transmitter 600 a(illustrated by overlapping beams 609 a, 610) off of the retro-reflector606, while the receiver 600 will not detect a reflection from the secondtransmitter 600 b.

[0111] In FIG. 21B, should an area of lower clearance than a ceiling ordoorjamb be detected, such as a table 611 or the like, some portions ofthe light emitted from both transmitters 600 a. 600 b will be detectedby the receiver 602, as illustrated by the arrows 609 ar, 609 br, beingwithin the range of the receiver beam 610.

[0112] As these transmitters 600 a, 600 b and receiver 602 are inelectronic communication with the control system 1000, the requisitesignals, based on whether or not light from zero, one or both sensorswas received, are sent to the control system 1000. This control system1000, as detailed above, will signal the drive system 1040 (FIG. 23)ceasing motion of the apparatus 20 or changing direction of theapparatus 20 as per the determined travel (cleaning) pattern, asdetailed below.

[0113] Similarly, the transmitters, receivers and reflector(s) can bereplaced by any combination of transmitters, receivers and reflectors,provided they function as detailed above.

[0114] Contour sensors 34, 35, are typically mounted laterally, at thesides of the apparatus 20 at upper and lower positions. These sensors34, 35 are used for detecting walls, furniture and other laterallypositioned obstacles. These sensors 34, 35, are typically formed of anultrasonic transmitter and an ultrasonic receiver. These contour sensorsare in communication with the control system 1000, and should a wall,furniture or other lateral obstacle be detected, the control system 1000will signal the drive system 1040 ceasing motion of the apparatus 20, asdetailed above.

[0115] Obstacle sensors 36 a, 36 b, 37 for detecting obstacles, such asfurniture, walls, or other obstacles, are typically arranged so as tocover the front of the apparatus 20. Here, front obstacle sensors 36 a,36 b are disposed high and low on the apparatus 20 with respect to eachother and in a substantially parallelogram-shaped pattern with respectto each other. The corner sensors 37, are in a relationship where theirsignals cross each other. For example, this crossing is typically at anapproximately 90 degree orientation. These obstacle sensors 36 a, 36 b,37 are typically ultrasonic transceivers, but other equivalent sensorsare also permissible. These obstacle sensors 36 a, 36 b, 37 are incommunication with the control system 1000, and should an obstacle bedetected, will send a signal to the control system 1000 accordingly,that will typically cease motion of the drive system 1040, as detailedabove.

[0116] For example, the obstacle sensors may be units, such as 40 Khzultrasonic transducer, Part No. 400PT160, from Prowave. These ultrasonicsensors 34, 35 36 a, 36 b, 37 define an array, and function as proximitysensors (of a proximity sensing system), that when coupled with thecontrol system, can provide a low resolution image of the obstacle pathin from of the apparatus 20.

[0117] Another sensor of the obstacle sensors is a sensor 38, typicallyfor horizontal object, for example, shelf, detection. This sensor 38typically includes a transmitter portion and a receiver portion,angularly upward (for example an angle of approximately 35 degrees withrespect to the horizontal). This sensor 38 is typically a PositionSensing Diode (PSD), formed from Infra red transmitting and receivingcomponents, and for example, may be a Sharp® infra-red sensor unit, PartNo. GP 2D12 14 from Sharp Electronics, Japan.

[0118] As the aforementioned ultrasonic sensors may not detect allhorizontal objects with small vertical portions, this sensor 38 providesthe requisite horizontal object detection. It also functions incombination with obstacle sensors 36 a, 36 b, 37 (and the control system1000) to create a local map. Should a low obstacle be detected, a signalwill be sent to the control unit 1000 that will signal the drive system1040 ceasing motion of the apparatus 20, as detailed above.

[0119] Turning FIG. 22A and 22B, sensors 620 (only one shown) (ranges ofeach sensor illustrated by beam projections 621), coupled to the controlsystem 1000, are for detecting height variances, typically associatedwith stair detection. These sensors 620 are typically attached onopposite sides of the extending portion 54, that extends from thechassis 50. These sensors 620 are typically position sensing diodes (asdetailed above). For example, the variance subject to detection wouldtypically occur with stairs, that is about 3 cm from the surface onwhich the apparatus 20 rides. With this variance detected, the sensors620 will signal the control system 1000, whereby the drive system 1040will cease motion of the apparatus 20, as it was too close to stairs orother downward decline in the surface.

[0120] There is also a full bin sensor system 1020 (FIG. 23), formed ofa transmitter 232 and receiver 233 positioned proximate to thefiltration unit 148 (detailed above). This full bin sensor system 1020is coupled to the control system 1000.

[0121] The remote control sensors 40 are typically an infra-red (IR)sensors. They are coupled to the control unit 1000 accepts commands fromthe remote controller 46, transmitted in the form of infra-red light.They are positioned frontally and laterally in the apparatus 20 (FIGS. 1and 13) to receive signals from the remote controller 46 regardless ofthe position of the apparatus 20.

[0122] The remote controller 46 is typically an infra-red remotecontroller (as detailed above) or the like. This remote controller 46can signal directly to the control system 1000 (as the remote controlsensor 40 is coupled to the control system 1000) various commands, suchas ON/OFF, various travel modes, various cleaning modes and patterns,strengths of cleaning, speed of the apparatus, etc.

[0123] For example, the control system 1000 can be programmed tofunction in a cleaning mode and pattern, where upon being signaled,typically by the remote controller 46, the apparatus 20, will “spotclean.” This involves small precise movements concentrated around asmall area for cleaning this small area. This concentrated cleaning mayinvolve high power suction by the apparatus 20 as it travels in small,typically overlapping, circles in a highly repetitious manner aroundthis small area.

[0124] For example, the control system 1000 can be programmed to performa travel mode, where once signaled, typically by the remote controller46, and the signal is received by one of the remote control sensors 40,the apparatus 20 navigates its way to a point proximate the remotecontroller 46, from its present location. This is known as the “call me”function, and typically is a dedicated key on the remote controller 46,but could also be a code or the like. Navigation and movement to thepoint proximate the remote controller 46 can be wholly or partially inaccordance with the sensors and associated systems and portions of theexemplary navigation program, detailed below (in blocks 1201-1244 ofFIG. 24). Navigation back to the point proximate to the remotecontroller can also be partially or wholly by a beam riding mechanism,where the beam from the remote controller 46 is tracked by the controlsystem 1000 and the apparatus 20 is rotated and maneuvered to the pointproximate the remote controller 46.

[0125]FIG. 23 is a schematic diagram of the control system 1000 of theapparatus 20. The control system 1000 includes a main processing board1002, that includes processing circuitry and other related circuitry,and a processor, such as a microprocessor (MP) 1004, that for example,serves as the central processing unit (CPU), for this main processingboard 1002. The microprocessor 1004 is preprogrammed as well as havingfunctionalities for receiving programs (typically entered through theremote controller 46 by the user). These programs may be for automaticor manual operation of the apparatus, or combinations thereof. Theapparatus 20 can also include storage media (not shown), coupled to thecontrol system 1000 or various components thereof. This storage mediastores data, such as scanning patterns for cleaning, sound samples,mapping functions, travel modes, etc. This microprocessor 1004 can be,for example, a Hitachi H8S2350 processor.

[0126] The navigation system and remote control command processing arethrough the microprocessor 1004. There functions, as well as others aredirectly integrated into the microprocessor 1004.

[0127] The control system 1000, and in particular the main processingboard 1002 and accordingly, the microprocessor 1004, are coupled tovarious components and systems, as detailed below. All below-listedcomponents and systems include the requisite associated electronics andelectronic couplings in order for proper operation with the mainprocessing board 1002 and microprocessor 1004. This control system 1000controls power distribution to all systems and components as well as alloperations thereof, for example, speeds, on/off, adjustments,positioning, etc. All components mentioned below, controlled by thecontrol system 1000 include the requisite electronics, circuitry,couplings, etc., so as to define systems controlled by the mainprocessing board 1002 and microprocessor 1004 of the control system1000.

[0128] The user interface 25 is electronically coupled (with therequisite associated electronics) to the main processing board 1002, andaccordingly, the microprocessor 1004). This main processing board 1002(and accordingly the microprocessor 1004) is also coupled to the doordetection sensors 30 a, 30 b, contour sensors 34, 35, obstacle sensors,36 a, 36 b, 37, Infra-red sensors, e.g., the sensor 38 and remotecontrol sensor 40, the stair detection sensors 620, and the full binsensing system 1020.

[0129] The main board 1002 and microprocessor 1004 are also coupled tothe steering system 1030, that includes left 1032 a and right 1032 bdrive motors and corresponding left 1034 a and right 1034 b odometers,associated with the respective drive wheels 72. This drive system 1040also includes the angle sensing system 1042 and odometry system 1044 ofthe guide wheel 74. The navigation system also couples to these steering1030 and drive 1040 systems through the main board 1002.

[0130] The main board 1002 and microprocessor 1004 also couple to apower system 1070, that include the batteries 86, and associatedelectronics, as well as the charging system 1074. The main board 1002and microprocessor 1004 also control power to and thus, speed of theimpeller motor 160 and agitator motor 308. There is also a coupling ofthe main board 1002/microprocessor 1004, with the “normally open” and“normally closed” electrical contacts defining the nozzle obstaclesensor system 1080 (detailed above). Similarly, there is a coupling ofthe main board 1002/microprocessor 1004 with the nozzle heightadjustment system 560, including the nozzle height adjustment motor 566and a nozzle height sensor 582, as well as the shock detection system1082, in particular, the sensors associated therewith (detailed above).

[0131] Additionally, there is a coupling to the leash system 1084, thatcontrols the leash 28 and associated components, that couples with theother systems, through the main board 1002/microprocessor 1004. The mainboard 1002/microprocessor 1004 can also couple to additional systems1090, that include for example, supplemental proximity sensing systems,supplemental navigation systems, etc.

[0132]FIG. 24A is a flow diagram indicating an example process ofnavigation and scanning for movement of the apparatus 20 for vacuumcleaning or the like. For example, this process 1200 can be implementedby the microprocessor 1004. It is typically preprogrammed therein andcoupled with the control system 1000 and main board 1002 will beperformed by the apparatus 20.

[0133] Initially the process 1200 begins at a START, block 1201,typically by activating the apparatus. The control system 1000, via themicroprocessor 1004 selects a footprint (path or scanning pattern) forthe movement of the apparatus 20, at block 1202. The system alwaysincludes a default footprint. Alternately, this footprint can beselected by the user, with the signals corresponding to the desiredfootprint entered into the control system.

[0134] The control system 1000, via the microprocessor 1004, thensignals the drive system 1040. This signal causes operation of the drivesystem 1040, where the apparatus 20 scans the immediate area inaccordance with the selected footprint, at block 1204.

[0135] The “footprint” for scanning is the pattern of movement of theapparatus. This pattern is typically triangular, and in particular inisocelises triangles. It can also be rectangular in linear movements.Scanning patterns are typically designed so as to be substantially freeof repetition. For example, scanning patterns may be as disclosed incommonly owned U.S. Pat. No. 6,255,793 and PCT patent applicationPCT/IL99/00248 (WO 99/59042), both of these documents incorporated byreference in their entirety herein.

[0136] The area being scanned is then monitored, at block 1206. Scanningcontinues until it is detected and signaled to the control system 1000,that the apparatus can no longer move laterally for scanning, at block1208. At block 1208, the scanning is ended, or the “end of sweep” hasbeen determined.

[0137] At this time, it is then determined, if an opening, suitable insize for the apparatus 20 to enter was detected during scanning(typically by contour sensors 34, 35, as shown in FIGS. 1 and 13), atblock 1210. If an opening of suitable size was not detected during thescan, it is then determined if the apparatus 20 has scanned for apredetermined time, area and or distance, or combination thereof, atblock 1220. This is in accordance with predetermined policies, typicallypreprogrammed into the microprocessor 1004.

[0138] If the scanning did not satisfy the predetermined condition, thescan direction is changed, at block 1222. The process then returns toblock 1202. Changing of the scanning direction, for example, can involvea turning movement of approximately 45 degrees by the apparatus 20, withscanning typically employing the same footprint, as was determined atblock 1202. Other turning angles are also permissible, and can beprogrammed or entered into the control system, for example, through theremote controller 46.

[0139] Returning to block 1210, If an opening was found, a contourmovement to the opening is signaled at block 1232. This contour movementinvolves the apparatus 20 moving along the sides or periphery (typicallydefined by the walls of the room or area), or proximate thereto(collectively, the “contour”), of the scanned area to look for theopening, as detected by the contour sensors 34, 35 (detailed above).Initially, if necessary, prior to the contour movement (based on theposition of the apparatus 20 upon reaching the end of sweep), theapparatus 20 moves to a point along or proximate the sides or peripheryfrom where the contour movement (to the opening) will begin. Once theopening is reached, the apparatus 20 is signaled (from the controlsystem 1000) to enter and move through the opening, at block 1234, bysensing the contour (by contour sensors 34, 35) and following it to thenext area to be cleaned (scanned). It is then determined if the openingis blocked, at block 1236. If the opening is not blocked, the processreturns to block 1204.

[0140] If the opening is blocked, the apparatus 20 is driven to returnto the beginning of the opening at block 1238, where the scanningdirection is changed, as the process returns to block 1222. With thescanning direction changed, the process returns to block 1202.

[0141] Returning to block 1220, if scanning satisfies the predeterminedparameters, a contour movement is signaled, at block 1242. This contourmovement involves the apparatus 20 moving along the sides, periphery orproximate thereto, of the scanned area (typically defined by the wallsof the room or area) to look for an opening, suitable for passage of theapparatus therethrough, at block 1244.

[0142] If an opening is found, the apparatus 20 is signaled (from thecontrol system 1000) to enter and move through the opening, at block1234. The process continues from this point (block 1234) as detailedabove.

[0143] If an opening was not found at block 1244, typically in apredetermined time period or scanned distance traveled (as for example,preprogrammed into the control system 1000), the process moves to block1222, where the scan direction is changed, as detailed above. Theprocess then returns to block 1202, as detailed above.

[0144] Alternately, the contour movements in blocks 1232 and 1242 can bereplaced with point to point navigation, as detailed above. Thedetermination as to whether to make a contour movement or point to pointnavigation can be programmed into the microprocessor 1004.

[0145] The above process 1200 repeats for as long as necessary,typically until a time out, power outage or deactivation (turned OFF) bythe user.

[0146]FIG. 24B is a flow diagram indicating another example process ofnavigation and scanning for movement of the apparatus 20 for vacuumcleaning or the like. For example, this process 1250 can be implementedby the microprocessor 1004. It is typically preprogrammed therein andcoupled with the control system 1000 and main board 1002 will beperformed by the apparatus 20.

[0147] Here, blocks 1201′, 1202′, 1204′, 1206′ and 1208′ are similar tocorresponding blocks 1201, 1202, 1204, 1208 and 1208, that have beendescribed above, those descriptions applicable here.

[0148] Once block 1208′ is complete, as lateral advancement for theapparatus 20 is no longer possible, here, the apparatus 20 havingreached the end of sweep, the process moves to block 1252. In block1252, there is performed a contour movement in accordance with thecoutour movements detailed above. Additionally, if necessary, prior tothe contour movement (based on the position of the apparatus 20 uponreaching the end of sweep), the apparatus 20 moves to a point along orproximate the sides or periphery from where the contour movement willbegin.

[0149] This contour movement can be for a predetermined or presetdistance. In this case, once the apparatus 20 has moved thepredetermined distance of the contour movement, the process returns toblock 1201′, whereby scanning of an area or portion thereof beginsagain. The process repeats for as long as necessary, typically until atime out, power outage or deactivation (turned OFF) by the user.

[0150] Alternately, this contour movement of block 1252, in particularits length or distance to be traveled “D” can be determined “on the fly”or dynamically, based on an estimate of the circumference or perimeterof the room, area, or portion thereof, to be or being scanned, inaccordance with following formula:

D=[K ₁ ·d][ΣL _(i)/max{L _(i) }]+[K ₂·max{L _(i)}]

[0151] where,

[0152] L_(i) is the series L₁ to L_(n), and L₁ to L_(n) are the lengthsof each straight line portion of the scanned pattern;

[0153] K₁ and K₂ can be, for example, K₁=0.8, K₂=1, where L_(i) aremeasured in meters; and

[0154] d is the diameter of the apparatus, for example apparatus 20,expressed in meters.

[0155] In accordance with the processes detailed in FIGS. 24A and 24B,the microprocessor 1004 is also programmed for all of the above detailedcleaning and travel modes and combinations thereof. The microprocessor1004 operates in conjunction with the main board 1002 and control system1000, for all of these additional cleaning and travel modes. Themicroprocessor 1004 is also programmed to determine distances traveledfor odometers of the drive 72 and guide wheels 74.

[0156] Turning to FIG. 25, there is detailed another function of theinvention. Here the apparatus 20 can be confined to specific areas, bythe placement of one or more coded transmitters 1300 at variouslocations in a room. The transmitter 1300 functions as a “virtual” wall.

[0157] Here, the apparatus is operating in a room 1302. It is desired tokeep the apparatus 20 in room portion QQ, and not let it travel to roomportion RR (separated by broken line 1304 for emphasis only).Accordingly, coded transmitter 1300 is positioned such that its “IN”beam 1308 is on the QQ side of the room 1302, while the “OUT” beam 1309is on the RR side of the room 1302.

What is claimed is:
 1. An apparatus for autonomous operation over anarea comprising: a drive system; and a controller in communication withsaid drive system, said controller including a processor programmed to:provide at least one scanning pattern for a first portion of said area;analyze said first portion for an opening to a second portion of saidarea; and signal said drive system to move along a path at leastproximate the periphery of said first portion to and through saidopening to said second portion of said area.
 2. The apparatus of claim1, wherein said processor is additionally programmed to provide at leastone scanning pattern for said second portion of said area.
 3. Theapparatus of claim 1, wherein said processor is additionally programmedto indicate the end of said at least one scanning pattern for said firstportion of said area when lateral advancement of said apparatus inaccordance with said at least one scanning pattern is no longerpossible.
 4. The apparatus of claim 1, wherein said at least onescanning pattern provided is substantially free of repetition.
 5. Theapparatus of claim 2, wherein said at least one scanning patternprovided is substantially free of repetition.
 6. The apparatus of claim1, wherein said movement at least proximate to said periphery of saidfirst portion includes a contour movement.
 7. An apparatus forautonomous operation over an area comprising: a drive system; and acontroller in communication with said drive system, said controllerincluding a processor programmed to: provide at least one scanningpattern for a portion of said area from a first point; signal said drivesystem to move along a path at least proximate the periphery of thescanned portion to a second point, said second point at a differentlocation than said first point; and provide at least one scanningpattern for a portion of said area from said second point.
 8. Theapparatus of claim 7, wherein said processor is programmed such thatsaid path includes a predetermined length.
 9. The apparatus of claim 7,wherein said processor is additionally programmed to dynamicallydetermine the length of said path.
 10. The apparatus of claim 9, whereinsaid length of said path (D) determined dynamically is in accordancewith the formula: D=[K ₁ ·d][ΣL _(i)/max{L _(i) }]+[K ₂·max{L _(i)}]where, L_(i) is the series L₁ to L_(n), and L₁ to L_(n) are the lengthsof each straight line portion of the scanned pattern; K₁ and K₂ can be,for example, K₁=0.8, K₂=1, where L_(i) are measured in meters; and d isthe diameter of the apparatus, for example apparatus 20, expressed inmeters.
 11. A nozzle for suction of particulates comprising: a body,said body including a first end and a second end, said first endincluding a neck, and said second end including an upper edge and alower edge defining an opening therebetween; a lip extending at leastsubstantially parallel to said opening along said upper edge andextending at least partially beyond said lower edge of said opening,said lip tapering upward from a portion of greater thickness to portionsof lesser thickness, said lip configured for creating a flow cavity tobe formed with the floor or surface over which said nozzle traverses.12. The nozzle of claim 11, wherein said lip is rounded in crosssectional shape.
 13. The nozzle of claim 11, wherein said lip and saidopening define a constant vertical aperture.
 14. The nozzle of claim 11,wherein said upper edge is along a first plane and said lower edge isalong a second plane, said first and second planes at leastsubstantially parallel with respect to each other.
 15. The nozzle ofclaim 11, wherein said body includes outwardly tapered sides, saidoutward tapering extending from said neck.
 16. A method for areacoverage by an autonomous machine comprising: scanning a first portionof said area in accordance with at least one scanning pattern; analyzingsaid first portion for an opening to a second portion of said area; andmoving along a path at least proximate to the periphery of said firstportion to and through said opening to said second portion of said area.17. The method of claim 16, additionally comprising: scanning saidsecond portion in accordance with at least one scanning pattern.
 18. Themethod of claim 16, additionally comprising: indicating the end of saidat least one scanning pattern for said first portion of said area whenlateral advancement of said apparatus in accordance with said at leastone scanning pattern is no longer possible.
 19. The method of claim 16,wherein said at least one scanning pattern is executed substantiallyfree of repetition.
 20. The method of claim 17, wherein said at leastone scanning pattern is executed substantially free of repetition. 21.The method of claim 16, wherein said movement at least proximate to saidperiphery of said first portion includes a contour movement.
 22. Amethod for area coverage by an autonomous machine comprising: scanning aportion of said area in accordance with at least one scanning pattern,from a first point; moving along a path at least proximate the peripheryof said scanned portion to a second point, said second point at adifferent location than said first point; and scanning a portion of saidarea in accordance with at least one scanning pattern, from said secondpoint.
 23. The method of claim 22, wherein said moving along said pathincludes moving a predetermined length.
 24. The method of claim 22,wherein said moving along said path includes determining the length ofsaid path dynamically.
 25. The method of claim 22, wherein saiddetermining the length of said path (D) dynamically is in accordancewith the formula: D=[K ₁ ·d][ΣL _(i)/max{L _(i) }]+[K ₂·max{L _(i)}]where, L_(i) is the series L₁ to L_(n), and L₁ to L_(n) are the lengthsof each straight line portion of the scanned pattern; K₁ and K₂ can be,for example, K₁=0.8, K₂=1, where L_(i) are measured in meters; and d isthe diameter of the apparatus, for example apparatus 20, expressed inmeters.
 26. An obstacle detection system for an autonomous cleaningmachine comprising: a control system; a nozzle, said nozzle including afirst end for receiving particulate inflow, and a second end forcommunicating with a suction generating unit, said second end includingarms; a height adjustment system coupled to said first end of saidnozzle, said height adjustment system in communication with said controlsystem; and receiver portions configured for receiving said arms in apivotal engagement, at least one of said arms and said respectivereceiver portions and said arms including first electrically conductingportions in electronic communication with said control system; and atleast one of said arms mounted in said respective receiver portion so asto define an open circuit when said at least one arm is at a firstposition in said respective receiver portion, and defining a closedcircuit when said at least one arm is at a second position, where saidfirst electrically conducting portions are in contact with each other.27. The apparatus of claim 26, additionally comprising a biasing memberin communication with said at least one arm and said respective receiverportion for maintaining said first position.
 28. The apparatus of claim27, wherein said biasing member includes a spring.
 29. The apparatus ofclaim 27, additionally comprising: second electrically conductingportions on at least one arm and said respective receiver portion, saidelectrically conducting portions in communication with said controlsystem; and said at least one arm mounted in said respective receiverportion so as to define a closed circuit when said arm is at said firstposition in said respective receiver portion, and defining an opencircuit when said at least one arm is at said second position, wheresaid second electrically conducting portions are out of contact witheach other.
 30. The apparatus of claim 29, wherein said control systemis configured to signal said height adjustment upon the detection ofeither of said closed circuit between said first electrically conductingmembers or said open circuit between said second electrically conductivemembers.
 31. An obstacle detection system for an autonomous cleaningmachine comprising: a control system; a nozzle, said nozzle including afirst end for receiving particulate inflow, and a second end forcommunicating with a suction generating unit, said second end includingarms; a height adjustment system coupled to said first end of saidnozzle, said height adjustment system in communication with said controlsystem; and receiver portions configured for receiving said arms in apivotal engagement, at least one of said arms and said respectivereceiver portions and said arms including first electrically conductingportions in electronic communication with said control system; and atleast one of said arms mounted in said respective receiver portion so asto define a closed circuit when said arm is at a first position in saidrespective receiver portion, and defining an open circuit when said atleast one arm is at a second position, where said first electricallyconducting portions are out of contact with each other.
 32. Theapparatus of claim 31, additionally comprising a biasing member incommunication with said at least one arm and said respective receiverportion for maintaining said first position.
 33. The apparatus of claim32, wherein said biasing member includes a spring.
 34. The apparatus ofclaim 32, additionally comprising: second electrically conductingportions on at least one arm and said respective receiver portion, saidelectrically conducting portions in communication with said controlsystem; and said at least one arm mounted in said respective receiverportion so as to define an open circuit when said arm is at said firstposition in said respective receiver portion, and defining a closedcircuit when said arm is at said second position, where said secondelectrically conducting portions are in contact with each other.
 35. Theapparatus of claim 34, wherein said control system is configured tosignal said height adjustment upon the detection of either of said opencircuit between said first electrically conducting members or saidclosed circuit between said second electrically conductive members.